Filling aluminum cans aseptically

Abstract

Methods of manufacturing shelf stable pods containing food or drink to be rapidly cooled, include inserting a mixing paddle into an aluminum can through an open end of a body of the can and sterilizing the can and mixing paddle at temperatures below a stress relief temperature of the can in a first aseptic chamber. The method also includes filling the can with a sterilized food or drink in the aseptic chamber, sealing a sterilized base of the can to the open end of the body of the can with a food-safe adhesive to create a hermetic seal, removing the can from the first aseptic chamber while maintaining the hermetic seal outside the first aseptic chamber, and mechanically seaming the base to the can.

What is claimed is: 
     
       1. A method of manufacturing shelf stable pods containing food or drink to be rapidly cooled, the method comprising:
 inserting a mixing paddle into an aluminum can through an open end of a body of the aluminum can, wherein the mixing paddle is inserted into the aluminum can before the aluminum can is moved into a first aseptic chamber; 
 sterilizing the aluminum can and mixing paddle at temperatures below a stress relief temperature of the aluminum can in the first aseptic chamber; 
 filling the aluminum can with a sterilized food or drink in the first aseptic chamber; 
 sealing a sterilized base of the aluminum can to the open end of the body of the aluminum can with a food-safe adhesive to create a hermetic seal; 
 removing the aluminum can from the first aseptic chamber while maintaining the hermetic seal outside the first aseptic chamber; and 
 mechanically seaming the sterilized base to the body of the aluminum can while maintaining the hermetic seal. 
 
     
     
       2. The method of  claim 1 , wherein removing the aluminum can and the sterilized base from the first aseptic chamber comprises moving the aluminum can and the sterilized base along a conveyor system. 
     
     
       3. The method of  claim 1 , further comprising:
 prior to sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive to create the hermetic seal, sterilizing the base in a second aseptic chamber; and 
 transporting the sterilized base into the first aseptic chamber while maintaining the sterilized base in aseptic conditions. 
 
     
     
       4. The method of  claim 1 , wherein the sterilized base is comprised of aluminum. 
     
     
       5. The method of  claim 1 , wherein the food-safe adhesive is a food safe resin compliant with FDA Part 175.105 or 21 CFR Part 175.105 or 177.1395. 
     
     
       6. The method of  claim 1 , further comprising adding liquefied gas into the body of the aluminum can prior to sealing the sterilized base to the open end of the body of the aluminum can. 
     
     
       7. The method of  claim 6 , wherein the liquefied gas is sterilized to eradicate microbial contamination prior to being added into the aluminum can. 
     
     
       8. The method of  claim 6 , wherein the liquefied gas is injected in an amount to generate an internal pressure of about 5 psi to about 50 psi above atmospheric pressure after the sterilized base is sealed to the open end of the body of the aluminum can. 
     
     
       9. The method of  claim 8 , wherein the internal pressure is maintained outside the first aseptic chamber while mechanically seaming the sterilized base to the body of the aluminum can. 
     
     
       10. The method of  claim 1 , wherein the mixing paddle is inserted into the aluminum can before the aluminum can is moved into the first aseptic chamber. 
     
     
       11. The method of  claim 1 , wherein sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying pressure to the sterilized base. 
     
     
       12. The method of  claim 11 , wherein sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying the food-safe adhesive to the aluminum can. 
     
     
       13. The method of  claim 11 , wherein sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying the food-safe adhesive to the sterilized base. 
     
     
       14. The method of  claim 1 , wherein seaming the sterilized base to the aluminum can comprises seaming the sterilized base to the aluminum can using a 2-roller can seamer. 
     
     
       15. The method of  claim 1 , wherein inserting the mixing paddle into the aluminum can through the open end of the body of the aluminum can comprises rotating the mixing paddle to partially thread a driveshaft connector and a nut together in a loose connection. 
     
     
       16. A method of manufacturing shelf stable pods containing food or drink to be rapidly cooled, the method comprising:
 inserting a mixing paddle into an aluminum can through an open end of a body of the aluminum can; 
 sterilizing the aluminum can and mixing paddle at temperatures below a stress relief temperature of the aluminum can in a first aseptic chamber; 
 filling the aluminum can with a sterilized food or drink in the first aseptic chamber; 
 sealing a sterilized base of the aluminum can to the open end of the body of the aluminum can with a food-safe adhesive to create a hermetic seal; 
 adding liquefied gas into the body of the aluminum can prior to sealing the sterilized base to the open end of the body of the aluminum can, wherein the liquefied gas is injected in an amount to generate an internal pressure of about 5 psi to about 50 psi above atmospheric pressure after the sterilized base is sealed to the open end of the body of the aluminum can; 
 removing the aluminum can from the first aseptic chamber while maintaining the hermetic seal outside the first aseptic chamber; and 
 mechanically seaming the sterilized base to the body of the aluminum can while maintaining the hermetic seal, wherein the internal pressure is maintained outside the first aseptic chamber while mechanically seaming the sterilized base to the body of the aluminum can. 
 
     
     
       17. The method of  claim 16 , wherein removing the aluminum can and the sterilized base from the first aseptic chamber comprises moving the aluminum can and the sterilized base along a conveyor system. 
     
     
       18. The method of  claim 16 , further comprising:
 prior to sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive to create the hermetic seal, sterilizing the base in a second aseptic chamber; and 
 transporting the sterilized base into the first aseptic chamber while maintaining the sterilized base in aseptic conditions. 
 
     
     
       19. The method of  claim 16 , wherein the sterilized base is comprised of aluminum. 
     
     
       20. The method of  claim 16 , wherein the food-safe adhesive is a food safe resin compliant with FDA Part 175.105 or 21 CFR Part 175.105 or 177.1395. 
     
     
       21. The method of  claim 16 , wherein the liquefied gas is sterilized to eradicate microbial contamination prior to being added into the aluminum can. 
     
     
       22. The method of  claim 16 , wherein the mixing paddle is inserted into the aluminum can before the aluminum can is moved into the first aseptic chamber. 
     
     
       23. The method of  claim 16 , wherein sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying pressure to the sterilized base. 
     
     
       24. The method of  claim 23 , wherein sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying the food-safe adhesive to the aluminum can. 
     
     
       25. The method of  claim 23 , wherein sealing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying the food-safe adhesive to the sterilized base. 
     
     
       26. The method of  claim 16 , wherein seaming the sterilized base to the aluminum can comprises seaming the sterilized base to the aluminum can using a 2-roller can seamer. 
     
     
       27. The method of  claim 16 , wherein inserting the mixing paddle into the aluminum can through the open end of the body of the aluminum can comprises rotating the mixing paddle to partially thread a driveshaft connector and a nut together in a loose connection. 
     
     
       28. A method of manufacturing shelf stable pods containing food or drink to be rapidly cooled, the method comprising:
 sterilizing a body of an aluminum can at temperatures below a stress relief temperature of the aluminum can in a first aseptic chamber of an aseptic filling system; 
 sterilizing a mixing paddle below a stress relief temperature of the mixing paddle in a second aseptic chamber of the aseptic filling system; 
 sterilizing a base below a stress relief temperature of the base in the aseptic filling system; 
 inserting the mixing paddle into the aluminum can through an open end of the body of the aluminum can in a primary aseptic chamber of the aseptic filling system; 
 aseptically filling the aluminum can with sterilized food or drink in the primary aseptic chamber; 
 securing the sterilized base to the open end of the body of the aluminum can with a food-safe adhesive to create a hermetic seal; 
 removing the aluminum can and the sterilized base from the primary aseptic chamber while maintaining the hermetic seal; and 
 seaming the sterilized base to the aluminum can. 
 
     
     
       29. The method of  claim 16 , wherein the food-safe adhesive is a food safe resin compliant with FDA Part 175.105 or 21 CFR Part 175.105 or 177.1395. 
     
     
       30. The method of  claim 29 , further comprising adding liquefied gas into the body of the aluminum can prior to securing the sterilized base to the open end of the body of the aluminum can. 
     
     
       31. The method of  claim 30 , wherein the liquefied gas is sterilized to eradicate microbial contamination prior to being added into the aluminum can. 
     
     
       32. The method of  claim 31 , wherein the liquefied gas is injected in an amount to generate an internal pressure of about 5 psi to about 50 psi above atmospheric pressure after the sterilized base is secured to the open end of the body of the aluminum can. 
     
     
       33. The method of  claim 32 , wherein the internal pressure is maintained outside the first aseptic chamber while mechanically seaming the base to the body of the aluminum can. 
     
     
       34. The method of  claim 33 , wherein securing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying the food-safe adhesive to the aluminum can. 
     
     
       35. The method of  claim 33 , wherein securing the sterilized base to the open end of the body of the aluminum can with the food-safe adhesive comprises applying the food-safe adhesive to the base. 
     
     
       36. The method of  claim 33 , wherein seaming the sterilized base to the aluminum can comprises seaming the sterilized base to the aluminum can using a 2-roller can seamer.